Dissolvable microneedles for skin treatment

ABSTRACT

A skin treatment device is provided including bioerodible polymeric microneedles which are designed to more effectively deliver beneficial agents to the skin. The device includes a flexible substrate and an arrangement, for example, an array, of microneedles projecting from the substrate.

This application is a continuation of U.S. patent application Ser. No.14/671,690, filed on Mar. 27, 2015, which claims priority to and thebenefit of U.S. Provisional Patent Application No. 61/972,165, filed onMar. 28, 2014, the entire disclosure of each of these applications beingincorporated herein by this specific reference.

The present invention generally relates to skin treatment andrejuvenation, and more specifically relates to a skin treatment deviceincluding polymeric microneedles, and methods of treating skin usingthese devices.

BACKGROUND

Human dermis is a layer of skin between the epidermis and subcutaneoustissue. The epidermis, serves as a barrier to protect the body againstmicrobial pathogens, oxidant stress (UV light), water loss and chemicalcompounds, and provides mechanical resistance. The subcutaneous tissueconsists of connective tissue and functions as a cushion for the bodyfrom stress and strain. The dermis is tightly connected to the epidermisthrough a basement membrane. Structural components of the dermis arecollagen, elastic fibers, glycosaminoglycan, and extra fibrillar matrix.The glycosaminoglycan, e.g. hyaluronan, has multiple functions such as,to ensure good hydration, to assist in the organization of theextracellular matrix (ECM), to act as a filler material, and toparticipate in tissue repair mechanisms. The extracellular matrix playsan important role in skin aging: in young skin, the collagen fibers forma three-dimensional network. The fibroblasts bind to collagen fibrilsvia multiple contact sites (integrins) on their surface. This bindingbuilds up a tensile stress, which balances the synthesis of collagen andcollagen-degrading matrix-metalloproteins in the fibroblasts. In agedskin, the structure of the extracellular matrix is damaged by collagenbreakdown—partial fragmentation of the collagen.

Skin aging is a progressive phenomenon, occurs over time and can beaffected by lifestyle factors, such as alcohol consumption, tobacco andsun exposure. Aging of the facial skin can be characterized by atrophy,slackening, and fattening. Atrophy corresponds to a massive reduction ofthe thickness of skin tissue. Slackening of the subcutaneous tissuesleads to an excess of skin and ptosis and leads to the appearance ofdrooping cheeks and eye lids. Fattening refers to an increase in excessweight by swelling of the bottom of the face and neck. These changes aretypically associated with dryness, loss of elasticity, and roughtexture.

To improve cell function of skin, there are two main approaches: one isto supply skin cells with essential building blocks through oralnutrition and supplements or topical creams and serums or vigorous dailyexercise to increase blood-flow and encourage the lymphatic system; theother approach relates to optimizing release of growth factors, i.e.substances that cause cells to differentiate, proliferate and/or grow,and cytokines which signal molecules released by cells to communicatewith other cells. However, applying active ingredients topically to skinin order to improve cell function has generally not been highlyeffective, likely due to the impermeable nature of stratum corneum andother superficial layers of the epidermis.

Non-invasive or low-invasive techniques and devices for facilitatingdelivery of beneficial agents into skin have been proposed. For example,microneedle devices have been used to create numerous shallow puncturesin the dermis, with the goal of enabling better penetration of topicalcompositions into the punctured skin. Such microneedle devices are usedto perforate the skin and topical compositions are then sometimesapplied to the punctured skin.

There remains an unmet need for better methods, devices and treatmentsfor improving skin conditions, for example, in order to optimize skinhealth and improve outward appearance.

SUMMARY

The present invention provides methods, devices and treatments forbenefitting skin, for example, by enhancing penetration of skin for moreeffective delivery of drugs, pharmaceuticals, antioxidants, vitamins,and other beneficial agents.

In one embodiment, a skin treatment device is provided. The device mayinclude microneedles which are designed to more effectively deliverbeneficial agents to the skin. The device may comprise a substrate, andan arrangement, for example, an array of microneedles projecting fromthe substrate. The microneedles may be comprised of a biodegradablepolymer, for example, a polysaccharide, for example, hyaluronic acid.The microneedles may further include an additive, for example, a vitaminor other beneficial agent.

The device is preferably designed such that the arrangement ofmicroneedles will facilitate penetration of the microneedles into theskin, for example into the stratum corneum, when the device is appliedto the skin. For example, in some embodiments, the arrangement ofmicroneedles comprises microneedles having different lengths from oneanother. For example, the array may comprise alternating first andsecond microneedles, wherein the first microneedles have a first lengthand second microneedles have a second length different from the firstlength.

In some embodiments, the device may include a first region sized and/orshaped to cover a first portion of skin to be treated, and a secondregion adjacent and connected to the first region, the second regionsized and/or shaped to cover a second portion of skin to be treated. Insome embodiments, the first region includes first microneedlesprojecting from the substrate and having a first length, and the secondregion includes second microneedles projecting from the substrate andhaving a second length, different from the first length, projecting fromthe first region and second microneedles having a second heightdifferent from the first height, projecting from the second region.

Methods of treating skin are also provided. In one embodiment, a methodof treating skin comprises the step of facilitating penetration ofmicroneedles into skin by drawing an area of skin to be treated towardan array of microneedles, for example using suction or a vacuum.

In yet another aspect of the invention, a skin treatment assembly isprovided comprising a first patch having a first shape for covering aportion of a face to be treated and including a first array ofmicroneedles and a second patch having a second shape different from thefirst shape for covering another portion of a face to be treated andincluding a second array of microneedles different from the first array.

In some embodiments, the first array comprises microneedles having afirst length and the second array comprises microneedles having a secondlength different from the first length. In other embodiments, the firstarray comprises microneedles having a first spacing and the second arraycomprises microneedles having a second spacing different from the firstspacing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be more readily understood and/or theadvantages thereof better appreciated by considering the followingDetailed Description and accompanying drawings of which:

FIG. 1 shows an SEM image of a portion of a PRIOR ART microneedledevice;

FIGS. 2a-2c illustrate, in simplified form, the mechanism of action ofthe PRIOR ART microneedle device shown in FIG. 1;

FIGS. 3a-3c illustrate, in simplified form, a mechanism of action of amicroneedle device of an embodiment of the present invention;

FIG. 4 shows a balloon representing skin, being pressed against an arrayof nails representing a PRIOR ART microneedle array;

FIGS. 5a and 5b show, in simplified form, an array of microneedles insome embodiments of the invention, and penetration of skin thereby;

FIGS. 6a and 6b show, in simplified form, an array of microneedles inother embodiments of the invention, and penetration of skin thereby;

FIG. 7 shows yet another embodiment of the invention;

FIG. 8 illustrates an assembly in accordance with some embodiments ofthe invention, useful for treating skin using layered microneedledevices;

FIGS. 9 and 10 illustrate, in simplified form, embodiments of theinvention using negative pressure to enhance effectiveness of thepresent invention; and

FIGS. 11, 12 and 13 illustrate yet other embodiments of the invention.

DETAILED DESCRIPTION

Turning to FIG. 1, a SEM image of a portion of a PRIOR ART microneedledevice 1 is shown. The microneedles 2 have a uniform length, shape andspacing. As illustrated in FIG. 2a through 2c , the microneedles 2 aregenerally used to prick or penetrate skin 3 at very superficial, shallowdepths (FIG. 2a ), to mechanically make the skin 3 more porous (FIG. 2b) and, theoretically, to permit penetration of topical agents 4 into thedeeper layers of the skin (FIG. 2c ).

In accordance with the present invention, polymeric microneedles, andarrays of such microneedles, coupled with both simple and complexgeometries and arrangements, have been developed for more effectivelydelivering pharmaceuticals, drugs, and other beneficial agents to skin.Delivery of such agents and ingredients may enhance the look and feel ofthe skin, by promoting hydration and improving skin texture andelasticity.

In one aspect of the invention, the microneedles comprise abiocompatible polymeric material. In some embodiments, the microneedlescomprise a polymeric material that is biodegradable or dissolvable inskin. In some embodiments, the microneedles comprise a mixture of apolymeric material and an active agent beneficial to skin.

Suitable polymeric materials include polymethylmethacrylate (PMMA),poly(glycolic acid-co-lactic acid) (PLGA), polyethylene (PE),polycaprolactone (PCL), polypropylene. The polymeric materials maycomprise a glycosaminoglycans (GAG), such as hyaluronan, chondroitin,heparin, collagen, fibroin, elastin, various polysaccharides, cellulosederivatives, and the like. In some embodiments, the microneedlescomprise a blend or combination of different polymers.

The beneficial agent may be any beneficial ingredient for improvingskin, for example improving skin health, texture, hydration, orelasticity. Such agents include vitamins (for example, A, C, B),antioxidants, skin-whitening agents, peptides and growth factors.

In some embodiments, the polymeric material is a polysaccharide, forexample, hyaluronic acid. In some embodiments, the beneficial agent andthe polymeric material are both hyaluronic acid. In some embodiments,the polymeric material is a crosslinked polymer, for example,crosslinked hyaluronic acid. Crosslinking of hyaluronic acid may beaccomplished in any suitable manner known to those of skill in the art.

To make the present microneedle devices, a precursor composition isprovided, for example, a polymeric gel composition including, orwithout, one or more beneficial additives. The precursor composition maybe made using known techniques for example, known techniques for makinghyaluronic acid-based dermal filler gels. The gel may be formed into gelmicroneedles using, for example, micromolding technologies. Themicroneedles project from a substrate to facilitate handling. Thesubstrate may be the same material as the microneedles, or may be adifferent material. The substrate may be any suitable flexiblesubstrate, such as a fabric, sheet or membrane. The formed gelmicroneedles may be then be allowed to become, or may be caused tobecome, dried, hardened projections that will penetrate skin.

Hyaluronic acid is a non-sulfated glycosaminoglycan that enhances waterretention and resists hydrostatic stresses. It is non-immunogenic andcan be chemically modified in numerous fashions. Hyaluronic acid may beanionic at pH ranges around or above the pKa of its carboxylic acidgroups. Unless clearly indicated otherwise, reference to hyaluronicacid, hyaluronan, or HA herein may include its fully protonated, ornonionic form as depicted below, as well as any anionic forms and saltsof hyaluronic acid, such as sodium salts, potassium salts, lithiumsalts, magnesium salts, calcium salts, etc.

Turning now to FIGS. 3a-3c , in one aspect, a skin treatment device 10is provided which allows for a “poke, dissolve and release” mechanism.For example, the device 10 may comprise a substrate 11, and anarrangement, for example, an array, of microneedles 12 projecting fromthe substrate 11 (FIG. 3a ). The microneedles 12 comprise a polymericcomponent and an active pharmaceutical, drug or other beneficial agent.The agent may be combined with, mixed in, encapsulated, or crosslinkedwith or into, the polymer component. The microneedles 12 are structuredto be capable of penetrating the skin 3 (FIG. 3b ), for example, theepidermis, and are released in the tissues below the skin surface anddissolved (FIG. 3c ). Dissolution of the polymeric component of themicroneedle causes release of the beneficial agent into the skin, forexample, as the polymer breaks down, biodegrades or dissolves.

One drawback with PRIOR ART microneedle technology, such as themicroneedles shown with FIG. 1 described above is that all of theneedles are of the same shape, length and are uniformly spaced apart.However, the natural elasticity of skin often prevents individualneedles from effectively penetrating the skin. This concept isgraphically illustrated in FIG. 4. An inflated balloon 5 is used torepresent skin, and an array 6 of nails 7 with identical lengths is usedto represent a prior art microneedle device having microneedles all ofthe same length. As illustrated, the nail tips are generally unable topenetrate or puncture through the balloon 5, or at least not withoutsubstantial pressures being applied between the balloon and the array ofnails.

Advantageously, referring now to FIGS. 5a-5b , in some embodiments ofthe invention, a skin treatment device 20 is provided comprising amicroneedle array 22 comprising microneedles projecting from a substrate26. The microneedle array 22 comprises needles of differing or varyinglengths (sometimes referred to as “heights.” For example, the device 20comprises first microneedles 32 having a first length and secondmicroneedles 34 having a second length different from the first length.First microneedles 32 and second microneedles 34 may be disposed in analternating fashion, for example, in ones, twos, threes, or more. Themicroneedles 32, 34 may be arranged in a set pattern or may be arrangedrandomly.

In some embodiments, the first length is at least about 1% greater inlength than the second length. For example, in some embodiments, thefirst length is at least about 5%, at least about 10%, at least about20%, at least about 30%, at least about 40%, at least about 50%, atleast about 60%, at least about 70%, at least about 80%, at least about90%, at least about 100%, at least about 150%, at least about 200%, atleast about 300%, at least about 500%, at least about 800%, or at leastabout 1000% greater in length than the second length. In someembodiments, the first microneedles may have a length that is at leastabout 10% to about 200% greater than the length of the secondmicroneedles. For example, the first microneedles have a length that isabout 30%, or about 40%, or about 50%, or about 60%, or about 70%, orabout 80%, or about 90%, or about 100%, or about 110%, or about 120%, orabout 130%, or about 140%, or about 150%, or about 160%, or about 170%,or about 180%, or about 190%, or about 200% or greater than the lengthof the second microneedles.

The device 20 is structured to be more effective in penetrating skin 4,for example, relative to an otherwise identical PRIOR ART device 1having needles all of the same length, such as described above. Byalternating needle length, the pressure of individual tall needles, forexample, needles 32, is increased and therefore potentially increasesthe number and amount of microneedles ultimately capable of penetratingthe skin. This might be better appreciated by referring to FIG. 5 b.

The microneedles 32, 34 may comprise a mixture of a polymeric materialand an active agent beneficial to skin. The array 22 may be formed bymolding the microneedles 32, 34 using conventional molding techniques.

Another embodiment of the invention is shown in FIGS. 6a and 6b . Inthis case, a device 40, similar to device 20, is provided, whichcomprises array 41 comprising microneedles 42, 44, 46 of at least threeor more different lengths.

It is known that different areas of the facial skin have differentdermal thicknesses. For example, the tear troughs, that is, the skindirectly under the eyes, have extremely thin dermal layers, while thechin region of the face has a relatively thick dermis. It iscontemplated that by varying the multiple needle lengths, as describedherein, various devices in accordance with the invention can be madewhich provide a desired penetration profile of selected facial areas.

In some embodiments of the invention, microneedles are provided whichhave a beneficial depth of penetration, depending upon the patient'sage, skin type, and/or area of skin being treated. For example, in oneaspect of the invention, a skin treatment device is provided whichcomprises a substrate having a first region including microneedleshaving a first length, and a second region adjacent the first region andincluding microneedles having a second length that is different from thefirst length.

Turning now to FIG. 7, in another embodiment, a patch device 50 isprovided that includes certain regions with particular needle arrays,which takes into account variances in dermal thicknesses of a patient.This may facilitate efficient drug delivery to various areas of theface, for example. For example, device 50 is in the form of a patchhaving array 52 for the nose bridge, and a different array 54 for thethinner facial region adjacent the nose. The device 50 is thus in theform of a single patch that is capable of effectively delivering drugsor beneficial agents to different regions of the skin, in this case, thenose bridge and the cheeks and/or tear trough, at a depth of penetrationsuitable for the skin region, based on the different arrangements ofmicroneedles.

Generally, in order for microneedles to effectively dissolve and releasewithin the skin to provide a benefit for skin rejuvenation, the depth ofpenetration may be between about 25 μm to about 2000 μm, for example,about 100 μm to about 1000 μm. In some embodiments, the microneedleshave a length of less than 100 μm, and in some embodiments, themicroneedles have a length of greater than 1000 μm, for example, up toabout 2000 μm. In some embodiments, the microneedles, for example, thelongest microneedles in the arrangement, have a length of between about200 μm and about 600 μm, for example, about 400 μm, or even morespecifically, about 420 μm to about 480 μm.

In one embodiment, a skin treatment device in accordance with theinvention comprises a substrate and spaced apart hyaluronic acid-basedmicroneedles projecting from the substrate, wherein the microneedleshave a length of between about 420 μm and 480 μm, a base of betweenabout 200 μm and about 300 μm, for example, a base of about 270 μm, anda tip width of less than 20 μm, for example, a tip width of about 5 μm.

For use in the tear trough region, in one embodiment, the microneedles,for example, the first microneedles, have a length less than about 500μm, for example, between about 100 μm to about 500 μm, for example, alength of about 400 μm, for example, a length of about 300 μm, forexample, a length of about 200 μm. For use in the chin region, themicroneedles have a length greater than about 500 μm, for example, alength of between about 500 μm to about 2000 μm, for example, a lengthof about 600 μm, for example, a length of about 700 μm, for example, alength of about 800 μm, for example, a length of up to about 1000 μm, ofup to about 2000 μm.

In another embodiment, the first microneedles have a length of about1000 μm and the second microneedles have a length of about 500 μm. Forexample, the first microneedles may be in the region of the patch forapplication on the nose of the patient, where the skin in relativelythick, and the second microneedles may be in a region of the patch thatis intended for the regions of skin directly adjacent the nose, wherethe skin is relatively thin.

In other embodiments, the first microneedles have a length of about 800μm and the second microneedles have a length of about 200 μm. In yetanother embodiment, the first microneedles have a length of about 500 μmand the second microneedles have a length of about 300 μm.

It is further contemplated that the device may comprise microneedleshaving a third length different from the first and second length, and afourth length different from the first second and third lengths.

Spacing between adjacent microneedles may be uniform or non-uniformacross the microneedle arrangement. For example, in some embodiments,spacing between microneedles is substantially uniform. Spacing may bebetween about 100 μm and about 2000 μm, for example, 200 μm, about 300μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800μm, about 900 μm, about 1000 μm, about 1100 μm, about 1200 μm, about1300 μm, about 1400 μm, about 1500 μm, about 1600 μm, about 1700 μm,about 1800 μm, about 1900 μm, or about 2000 μm, or greater, betweenadjacent microneedles.

In yet another embodiment, illustrated in FIG. 8, the present inventionprovides a skin treatment device 70 comprising a plurality of stages, orlayers 72, 74, 76, 78. The layers 72, 74, 76, 78 may be designed to beapplied to the skin in an overlapping fashion. The device 70 providescustom treatment for a patient depending upon the type of skin, or theamount or type of active agent to be delivered. For example, device 70may be used to create different layered microneedle patches 80, 82, eachtailored to a patient's unique skin qualities.

Each of the layers, for example, layer 72, may comprise a substrate 72having spacing or perforations 72 and microneedles 72 a locatedgenerally between the spacing 72″. The needles 72 a may be throttled topermit a number of layers to be stacked on one another, with needles ofadjacent layers extending in the spacing between needles of otheradjacent layers.

For example, for use in a patient having a rougher, more deflectiveskin, layered patch 80 comprising fewer layers 72, 74, and thus a lowerdensity of needles, may be utilized to treat the skin. For a patienthaving a relatively softer skin, a patch 82 comprising more layers, suchas layers 72, 74, 76 and 78, and thus a higher density of needles, couldbe used to treat the skin. For example, a single layer, for example,layer 72 may be used for treatment of a patient having rough, moredeflective skin. A layered patch 80, comprising a combination of layer72 and layer 74, may be used for treatment of a patient havingsemi-rough, less deflective skin. A patient with relatively smooth skinmay be treated with a denser needle array, for example, a layered patch82 comprising a combination of layers 72, 74, 76 and 78.

The layers 72, 74, 76, 78 could be pre-assembled before being applied tothe skin, or could be layered during a treatment session while on theskin.

In some embodiments, each of layers 72, 74, 76 and 78 comprises adifferent specific needle length, such that when the layers are placedtogether, the assembly provides a desired treatment profile.

For example, layer 72 may include only relatively long needles 72 a andlayer 78 may comprise only relatively short needles 78 a. In someembodiments, each layer comprises needles of appropriate needle lengthto effectively deliver an equivalent amount of active agent per needle.

In some embodiments, each of layers 72, 74, 76 and 78 comprises adifferent, specific pharmaceutical, or other beneficial agent, such thatwhen the layers are placed together, the assembly provides a desiredtreatment profile, for example, made up of a combination of such agents.

For example, layer 72 may include needles 72 a comprising hyaluronicacid and Vitamin C as an active agent, while layer 74 includes needles74 a having hyaluronic acid and Vitamin E as an active agent. Thus,patch 80, comprising layered 72 and 74, can be used to deliver bothhyaluronic acid, Vitamin C and Vitamin E.

In yet another embodiment, as show in simplified form in FIG. 9, amethod of treating skin is provided. The method comprises drawing anarea of skin 3 to be treated toward a microneedle device, for example,device 10, or any other microneedle device in accordance with theinvention as described elsewhere herein. The method comprises usingnegative pressure, for example by means of a vacuum mechanism 90 havingvacuum chamber 92, in order to stretch the skin and enhance penetrationof microneedles into the skin 3. This method reduces deflection of theskin away from the needles and improves the number of needles thatpenetrate the skin and/or depth of needle penetration.

Any suitable vacuum or negative pressure mechanism may be used toaccomplish more effective needle penetration in accordance with thisembodiment. For example, in one embodiment, the vacuum mechanism 90includes essentially no moving parts, and vacuum chamber 92 suppliesnegative pressure to draw the surface of skin 3 toward microneedledevice 10. The microneedle device 10 can be flexibly sealed against thewalls of the chamber such as by means of a rubber or other suitablematerial gasket, thus allowing the device 10 to move toward skin whilemaintaining a vacuum.

As depicted in FIG. 9, the skin 3 may experience maximum deflection inthe central area within the vacuum chamber 92. It is contemplated thatin order to compensate for uneven deflection, the microneedles at theperimeter of the device 10 can be made longer than the needles in theinner portion thereof. Another means to address uneven skin deflectioncaused by the vacuum is to provide an appropriately sized vacuum area sothat the micro-needle penetration area is sufficient for therapeuticcoverage but small enough to permit consistency. For example, asillustrated in FIG. 10, multiple vacuum chambers 94, for example, sevenvacuum chambers, located within a single housing 96, may be used toprovide more consistent needle penetration and to enable coverage of alarger skin area in single application.

Turning now to FIG. 11, in yet another embodiment of the invention,device 110 of the invention is in the form of a stretchable mask. Device110 may be similar to devices 10, 20, 40, 50, 70, 80 and 82, and mayinclude one or more of the features already described. Device 110 mayhave substrate in a generic face shape, for example, with cutouts 112for the eyes, lips, and/or and any other areas. Either the substrateonly, or the entire device 110 including the microneedles, can be madeof a stretchable material. As illustrated, arrangements of microneedlesof the device 110 can be different for treating different locations ofthe face. For example, the needle length, density of needles, or needlegeometry can be altered depending on the region of the face they areintended to treat. For example, microneedles 112 a are provided fortreatment below the eye, microneedles 112 b are provided for treatmentof the cheek region, and microneedles 112 c are provided for treatmentof the chin region.

Alternatively, turning now to FIG. 12, instead of one large mask-likedevice such as shown in FIG. 11, in some embodiments, device 210 isprovided which comprises separate, discrete patches 212 are provided forspecific areas of the face. This is illustrated in FIG. 12. The abilityof the discrete patches to overlap allows the patches to accommodatemany potential face shapes and sizes. In this embodiment, area specificmicroneedle patches are applied independently across a patient's face.Each patch may include the same or different arrangements ofmicroneedles, for example, arrangements 212 a, 212 b, 212 c. Forexample, the needle length, density of needles, type or dosage ofbeneficial agent, or even needle geometry can be altered depending onwhere on the region of the face they will be used to treat.

Another embodiment, illustrated in FIG. 13, is provided which generallycomprises an assembly 310 comprising microneedle strips 312 which may beapplied to skin in rows, or other patterns, to obtain the precisecoverage desirable for a patient. Such strips 312 may be provided in theform of a roll 314 of tape 316. The tape 316 may have features thatindicate which side of the tape contains the microneedles. This may be acolor, text, or shape indication. This embodiment allows rapid largesurface area application over a wide variety of patient anatomies.

Similar to unique needle geometries among the face specific patchembodiments, several strip “types” may be provided that can be usedduring a single procedure. Each strip may be used on specific areas ofthe face, with needles on each strip with unique needle length, densityof needles, needle geometry, etc. The microneedle geometries may beunique to specific “tapes” to be applied on certain regions of the face.

EXAMPLE Preparation of Microneedle Device in Accordance with anEmbodiment, Using Hyaluronic Acid (HA)

Preparation of HA Gel Hydrate:

HA gel hydrates were made by hydrating low molecular weight (LMW) HA (Mwis about 340,000 to about 840,000 Da) in deionized (DI) water orphosphate buffered saline (PBS). For a 12 wt % of LMW HA, approximately1.20 g of LMW HA and 8.80 g of DI water were mixed in a 20 mL syringe.The mixture was left at room temperature for 24 hours to achieve auniform hydrogel. The gel was then transferred to a 1.0 mL syringes andcentrifuged at 4000 rμm for 5.0 min.

HA Gel Casting:

The casting of HA gel includes two steps, casting and pre-concentrating.In the casting step, HA gel was cast on the negative siliconemicroneedle mold and upon evaporation of water at room temperature or inan oven, the solution formed a viscous paste on the top of the mold. Forexample, 0.65 mL of a 12 wt % HA gel was cast onto the center of thenegative silicone mold. The gel together with the silicone mold wasplaced into an oven which was pre-set at 40° C. After 1.50 hours ofincubation, the gel formed a paste and was removed from the oven for thecompression step.

Pressing and Post-Incubation:

The HA paste together with the negative silicone microneedle mold wasplaced on a compressor. A PTFE film was placed on top of the HA paste.The compression pressure was set to 20 psi initially, then increased to50 psi at a constant rate over a period of 30 seconds and held at thispressure for another 30 seconds.

Needle Formation:

After pressing, the PTFE film was removed and a flat layer of HAremained on top of the mold. The mold was then placed into a 40° C. ovenfor 2.5 hours. The dried micro-needle batch was then removed from themold and sent for characterizations by SEM and x-ray CT.

Although the various embodiments of the invention have been describedand illustrated with a certain degree of particularity, it is understoodthat the present disclosure has been made only by way of example, andthat numerous changes in the combination and various arrangement ofparts, features and components can be resorted to by those skilled inthe art without departing from the scope of the invention, ashereinafter claimed.

What is claimed is:
 1. A method for manufacturing a microneedle devicecomprising the steps of: providing a precursor composition comprising ahyaluronic acid (HA) gel hydrate; casting the precursor composition ontoa negative microneedle mold, the mold defining a microneedle array;partially dehydrating the precursor composition to provide apre-concentrated composition; compressing the pre-concentratedcomposition; drying the pre-concentrated composition thereby forming asolid microneedle array; and removing the solid microneedle array fromthe negative microneedle mold.
 2. The method of claim 1, wherein thestep of providing a precursor composition comprises mixing a HA in anaqueous medium to form a mixture and allowing the mixture toequilibrate, thereby forming a uniform hydrogel.
 3. The method of claim2, wherein the HA is a low molecular weight HA having a molecular weightin the range of about 340,000 Da to about 840,000 Da.
 4. The method ofclaim 2, wherein the aqueous medium is selected from deionized water andphosphate buffered saline (PBS).
 5. The method of claim 2, wherein theHA is selected from the group consisting of a fully protonatedhyaluronic acid; a deprotonated hyaluronic acid; a salt of hyaluronicacid; and combinations thereof.
 6. The method of claim 1, wherein thestep of partially dehydrating the precursor composition comprisesevaporation of water at room temperature.
 7. The method of claim 1,wherein the step of partially dehydrating the precursor compositioncomprises incubating the HA gel hydrate and negative microneedle mold inan oven.
 8. The method of claim 7, wherein the oven has been preheated.9. The method of claim 7, wherein the incubating is performed at atemperature of 40° C.
 10. The method of claim 7, wherein the incubatingis performed for a period of about 1.5 hours.
 11. The method of claim 1,wherein the negative microneedle mold is a silicone mold.
 12. The methodof claim 1, wherein the negative microneedle mold is configured toproduce a microneedle array comprising microneedles having a length ofabout 25 μm to about 2000 μm.
 13. The method of claim 1, wherein thenegative microneedle mold is configured to produce a microneedle arraycomprising first microneedles having a first length and secondmicroneedles having a second length different from the first length,wherein in a side view, the first microneedles are arranged with thesecond microneedles along a substrate in a set pattern, the firstmicroneedles having a length of between 200 μm and 2000 μm.
 14. Themethod of claim 13, wherein the set pattern consists of the first andsecond microneedles arranged in an alternating fashion.
 15. The methodof claim 1, wherein the step of compressing the pre-concentratedcomposition comprises applying a film on top of the pre-concentratedcomposition prior to compressing the pre-concentrated composition. 16.The method of claim 15, wherein the step of compressing thepre-concentrated composition comprises applying an initial compressionpressure, incrementally increasing the compression pressure at aconstant rate until a predetermined maximum compression pressure isachieved, and maintaining the compression pressure at the predeterminedmaximum pressure for a period of time.
 17. The method of claim 16,wherein the initial compression pressure is 20 psi, the predeterminedmaximum compression pressure is 50 psi, and the period of time is about30 seconds.
 18. The method of claim 1, wherein the step of drying thepre-concentrated composition comprises incubating at 40° C. for about2.5 hours.
 19. The method of claim 1, wherein the precursor compositionfurther comprises an active agent beneficial to skin.
 20. The method ofclaim 19, wherein the active agent is selected from the group consistingof vitamins, antioxidants, skin-whitening agents, peptides, and growthfactors.